Method and system for recapturing and reusing unreacted antimicrobial solutions in spray applications

ABSTRACT

A system providing for on-site reclamation and re-use of reclaimed antimicrobial solution includes a dispenser, at least one receptacle, piping, and at least one pump. The dispenser sprays antimicrobial solution toward moving raw food products. Unspent antimicrobial solution that did not contact the moving raw food products and rebound antimicrobial solution that did contact the raw food products combine to form a reclaimed antimicrobial solution. The reclaimed antimicrobial solution is collected in the receptacle and is pumped through the piping to a location for reuse.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.12/702,057 filed Feb. 8, 2010, published as US2010/0136189-A1, which isa divisional application of U.S. application Ser. No. 11/335,239 filedJan. 19, 2006, and issued as U.S. Pat. No. 7,870,822 on Jan. 18, 2011.The entire disclosures of which are hereby expressly incorporated hereinby reference including, without limitation, the specification, claims,and abstracts, as well as any figures, tables, or drawings thereof.

BACKGROUND OF THE INVENTION

The present invention relates to the field of food processing. Inparticular, the present invention relates to a system and a method foron-site reclamation and reapplication of raw food product antimicrobialsolution.

One of the stages in raw food product processing is disinfecting the rawfood product in order to reduce or control microbial populations on thesurface of the raw food products. During the disinfecting stage, thesurface of the raw food product is sprayed with a disinfecting solution,typically an antimicrobial solution, to kill or remove organics andinorganics, both dissolved and particulate, from the surface of the rawfood product. The raw food product (e.g., poultry, beef sides orproducts, fruits, vegetables) is moved through the processing systemalong an automated device, such as a conveyor rail, and is sprayed bystationary or moving spray nozzles positioned on either side of theconveyor rail. Antimicrobial solution is applied onto the raw foodproducts through the spray nozzles to reduce microbial populations onthe raw food product. Thus, as the raw food product travels along theconveyor rail, it is sprayed with antimicrobial solution from variousdirections. While the spray nozzles usually provide a continuous spray,the raw food products are typically spaced apart from one another asthey move along the conveyor rail. Thus, as the raw food products travelalong the conveyor rail, a portion of the spray volume will contact thesurfaces of the raw food products and a portion of the spray volume willpass through the spaces between the raw food products.

Although recycling the entire runoff of the antimicrobial solution istechnically feasible, current systems are complex, time-consuming, andnot cost-effective. The recaptured antimicrobial solution must befiltered and treated to remove soluble organics as well as particulatesremoved from the surface of the raw food products to meet regulatoryparameters set by the United States Department of Agriculture (USDA)prior to reuse. A widely used antimicrobial solution is acidified sodiumchlorite (ASC). Fresh ASC antimicrobial solution must meet FDA approvals(21 C.F.R. 173.325) as well as industry standards. Immediately aftermixing the sodium chlorite with an acid solution, a certain amount ofchlorous acid is formed. After contacting the surfaces of the raw foodproducts, the concentration of chlorous acid and sodium chloritedecreases, making the solution less effective. This typically occurs intwo ways. First, a portion of the chlorous acid in the antimicrobialsolution reacts with organics and inorganics on the surface of the rawfood product, decreasing the sodium chlorite concentration of the spentsolution. Second, some raw food products exude sera or other materialsthat buffer and/or consume some of the acidity of the antimicrobialsolution such that the pH of the spent solution is higher than theinitial pH of the solution.

BRIEF SUMMARY OF THE INVENTION

A system providing for on-site reclamation and re-use of reclaimedantimicrobial solution includes a dispenser, at least one receptacle,piping, and at least one pump. The dispenser sprays antimicrobialsolution toward moving raw food products. Unspent antimicrobial solutionthat did not contact the moving raw food products and reboundantimicrobial solution that did contact the raw food products combine toform a reclaimed antimicrobial solution. The reclaimed antimicrobialsolution is collected in the receptacle and is pumped through the pipingto a location for reuse.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an overhead view of a disinfecting stage of an antimicrobialsolution reapplication system.

FIG. 2 is a diagram of the antimicrobial solution reapplication systemof the present invention.

FIG. 3 is a block diagram of the antimicrobial solution reapplicationsystem of the present invention.

DETAILED DESCRIPTION

FIG. 1 is an overhead view of a disinfecting stage of an antimicrobialsolution reapplication system 10 in accordance with the presentinvention. Reapplication system 10 is an antimicrobial solutionreclamation and reapplication system that permits the reuse of reclaimedantimicrobial solution during raw food processing by reclaiming unspentantimicrobial solution as well as some spent antimicrobial solution.Reapplication system 10 is beneficial for reducing antimicrobialsolution consumption through more efficient utilization of antimicrobialsolution, which in turn also decreases the impact on the environment.Although the specification discusses the reclamation and reapplicationof antimicrobial solution, those skilled in the art will recognize thatthe system and method can be used for the reclamation and reapplicationof any sprayed-on additive.

FIG. 1 specifically shows a first disinfecting stage 12 of reapplicationsystem 10. Disinfecting stage 12 removes organics, inorganics, and otherparticulates from raw food product 14 and generally includes conveyorrail 16, opposing first wall 18 a and second wall 18 b, spray nozzles20, first receptacle 22 a and second receptacle 22 b, and circulationsystem 24 (shown and described in FIG. 2). Conveyor rail 16 ispositioned between opposing first and second walls 18 a and 18 b andmoves raw food product 14 through disinfecting stage 12.

Spray nozzles 20 are positioned along opposing first and second walls 18a and 18 b of disinfecting stage 12 and contain antimicrobial solutionfor disinfecting raw food product 14. As raw food product 14 moves alongconveyor rail 16, spray nozzles 20 continuously spray antimicrobialsolution towards raw food product 14. Antimicrobial solution is sprayedfrom spray nozzles 20 at a force sufficient to propel the droplets ofantimicrobial solution to raw food product 14 as well as the opposingwall. Although FIG. 1 depicts spray nozzles 20 in staggered positionsalong opposing first and second walls 18 a and 18 b, spray nozzles 20can be positioned along first and second walls 18 a and 18 b in avariety of arrangements as long as the droplets of antimicrobialsolution leaving spray nozzles 20 are not prevented from reaching eitherraw food product 14. Additionally, although FIG. 1 depicts spray nozzles20 positioned along first and second walls 18 a and 18 b, spray nozzlescan also be positioned on the ceiling or floor, as long as theantimicrobial solution is directed to contact raw food product 14.

First and second receptacles 22 a and 22 b are positioned directly belowspray nozzles 20 along first and second walls 18 a and 18 b,respectively. As antimicrobial solution is sprayed toward raw foodproduct 14, a portion of the antimicrobial solution will contact rawfood product 14 (spent antimicrobial solution) and adhere to the surfaceof raw food product 14. Because raw food products 14 are spaced alongconveyor rail 16 at a distance from one another, a portion of theantimicrobial solution will not contact raw food products 14 (unspentantimicrobial solution). The unspent antimicrobial solution thuscontinues past conveyor rail 16 and raw food product 14. The unspentantimicrobial solution from spray nozzles 20 positioned along first wall18 a continues toward opposing second wall 18 b, while the unspentantimicrobial solution from spray nozzles 20 positioned along secondwall 18 b continues toward opposing first wall 18 a. Once the unspentantimicrobial solution contacts respective opposing first or second wall18 a and 18 b, the unspent antimicrobial solution runs down first orsecond wall 18 a and 18 b and into first and second receptacles 22 a and22 b, respectively. Although FIG. 1 depicts first and second receptacles22 a and 22 b positioned directly below spray nozzles 20, first andsecond receptacles 22 a and 22 b can be positioned at differentlocations as long as first and second receptacles 22 a and 22 b arepositioned to receive the unspent antimicrobial solution after it issprayed at raw food products 14.

When the antimicrobial solution contacts raw food product 14, thechemicals in the antimicrobial solution react with dissolved organics,inorganics, and/or particles on the surface of raw food product 14 andare typically not be reused without first being reconditioned. Incontrast, the unspent antimicrobial solution collected in first andsecond receptacles 22 a and 22 b are not significantly degraded becauseit never contacted raw food product 14 and did not undergo any chemicalreactions, such as oxidation or reduction. In addition, the unspentantimicrobial solution will not be buffered outside any pHspecifications that may be set by the FDA and/or USDA. Some spentantimicrobial solution containing organic contaminants and particulates(rebound antimicrobial solution) will also be collected into first andsecond receptacles 22 a and 22 b along with the unspent antimicrobialsolution through deflection or rebound off raw food product 14, orthrough other means. Although a portion of the rebound antimicrobialsolution is mixed with the unspent antimicrobial solution (reclaimedantimicrobial solution) in first and second receptacles 22 a and 22 b,the level of organic contaminants and particulates in the reclaimedantimicrobial solution is still less than the level of organiccontaminants and particulates that would be present in a solutioncombining all of the spent antimicrobial solution and all of the unspentantimicrobial solution. After the reclaimed antimicrobial solution hasbeen collected, the reclaimed antimicrobial solution is typically sentthrough a reconditioning step, such as filtration, prior to reuse inorder to satisfy USDA standards and regulations. Optionally, if thelevel of organic contaminants and particulates in the reclaimedantimicrobial solution satisfies USDA standards and regulations, thereclaimed antimicrobial solution can be immediately reused withoutreconditioning.

Examples of suitable antimicrobial solutions include, but are notlimited to: octanoic acid, acetic acid, acidified sodium chlorite,carnobacterium maltaromaticum stain CB1; cetylpyridinium chloride;citric acid; chlorine dioxide; 1,3 di-bromo-5, 5-dimethylhydantoin;citric acid, phosphoric acid, and hydrochloric acid mixtures; lacticacid; lactoferrin; lauramide arginine ethyl ester; nisin, ozone;hydrogen peroxide; peroxyacetic acid; peroxyoctanoic acid; potassiumdiacetate; lactic acid and acidic calcium sulfate mixtures; lactic acid,acidic calcium sulfate, and propionic acid mixtures; lactic acid,calcium sulfate, and sodium phosphate mixtures; sodium metasilicate;trisodium phosphate; or combinations thereof. An example of a suitablecommercially available antimicrobial solution includes, but is notlimited to, trade designated SANOVA® acidified sodium chlorite,available from Ecolab, Incorporated, Saint Paul, Minn.

FIG. 2 is a diagram of reapplication system 10 showing disinfectingstage 12, which includes spray nozzles 20 and first and secondreceptacles 22 a and 22 b, circulation system 24, and raw foodprocessing stage 26. Circulation system 24 generally includes piping 28and pump 30. Circulation system 24 circulates the reclaimedantimicrobial solution through reapplication system 10. Piping 28 ofcirculation system 24 generally includes collection line 28 a,intermediate line 28 b, T-line 28 c, recycle line 28 d, and secondaryline 28 e. Collection line 28 a connects disinfecting stage 12 and pump30. First intermediate line 28 b connects pump 30 to T-line 28 c, whichis connected to recycle line 28 d and secondary line 28 e. When thereclaimed antimicrobial solution comes to T-line 28 c, the reclaimedantimicrobial solution can be passed to recycle line 28 d, secondaryline 28 e, or both recycle line 28 d and secondary line 28 e. Recycleline 28 d connects T-line 26 c and disinfecting stage 12. Secondary line28 e connects T-line 28 c and raw food processing stage 26. Pump 30pumps the unspent solution collected in first and second receptacles 22a and 22 b through piping 28.

After the mixture of unspent and rebound antimicrobial solution has beenreclaimed by first and second receptacles 22 a and 22 b (shown in FIG.1), circulation system 24 of reapplication system 10 transports thereclaimed antimicrobial solution back to disinfecting stage 12 or rawfood processing stage 26 for reuse. Optionally, reapplication system 10can also include a reconditioning stage upstream of food processingstage 26 or disinfecting stage 12.

FIG. 3 is a block diagram of reapplication system 10 showing first foodprocessing stage 26 a, second food processing stage 26 b, disinfectingstage 12, and third food processing stage 26 c. During raw foodprocessing, the raw food product is passed through numerousfood-processing stages in preparation for human consumption. First andsecond food processing stages 26 a and 26 b occur prior to disinfectingstage 12 and can be any number of food processing steps whereantimicrobial solution is needed. For example, first or second foodprocessing stages 26 a and 26 b can include stripping the raw foodproduct of any undesirable exterior protection, such as, but not limitedto: removing hides from red meat carcasses, removing feathers frompoultry products, or removing stems from fruit or vegetable products.First and second food processing stages 26 a and 26 b can also includeeviscerating the raw food product, including, but not limited to,removing the guts of red meat carcasses or poultry products.

Third food processing stage 26 c occurs after disinfecting stage 12 andcan include any number of food processing steps where antimicrobialsolution is needed. For example, third food processing stage 26 c caninclude applying antimicrobial solution to a raw food product after ithas been stripped of any undesirable products and is ready for humanconsumption, including, but limited to, a cold carcass application ofantimicrobial solution.

After antimicrobial solution has been sprayed in disinfecting stage 12,the reclaimed antimicrobial solution is collected for transport andreuse in various raw food processing stages of reapplication system 10.Circulation system 24 (shown in FIG. 2) transports the reclaimedantimicrobial solution to any raw food processing stage in reapplicationsystem 10 requiring antimicrobial solution, including first, second, andthird food processing stages 26 a, 26 b, and 26 c. The reclaimedantimicrobial solution can also be transported back to disinfectingstage 12 for reuse. While FIG. 3 depicts recapturing the reclaimedantimicrobial solution for reuse only during disinfecting stage 12 ofreapplication system 10, the reclaimed antimicrobial solution can berecaptured and reused during any stage of reapplication system 10.Additionally the reclaimed antimicrobial solution can be sent through afiltering stage prior to reuse.

The reclaimed antimicrobial solution recapture and reapplication systemof the present invention collects the reclaimed antimicrobial solutionfrom a raw food processing stage and transports the reclaimedantimicrobial solution to the reapplication system for reuse. Duringnumerous stages of raw food processing, antimicrobial solution issprayed toward a raw food product for disinfection. A portion of theantimicrobial solution contacts the raw food product and reacts withorganics, inorganics, and other particulates on the surface of the rawfood product to disinfect the raw food product. Another portion of theantimicrobial solution does not contact the raw food product and remainsin substantially fresh condition. The unspent antimicrobial solution,along with any rebound antimicrobial solution is collected andtransported through a circulation system of the reapplication system toa raw food processing stage for reuse.

Although the present invention has been described with reference topreferred embodiments, workers skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the invention.

1-5. (canceled)
 6. A method for on-site reclamation of antimicrobialsolution in a raw food product processing system, the method comprising:(a) spraying an antimicrobial solution toward raw food products during adisinfecting stage with a plurality of spray nozzles; (b) collectingboth unspent antimicrobial solution that did not contact the raw foodproducts and a portion of rebound antimicrobial solution that didcontact the raw food products to form a reclaimed antimicrobial solutionin a first receptacle positioned directly below a first portion of theplurality of spray nozzles and a second receptacle positioned directlybelow a second portion of the plurality of spray nozzles; (c) pumpingthe reclaimed antimicrobial solution from the first receptacle and thesecond receptacle through piping; (d) optionally filtering the reclaimedantimicrobial solution through a filtration system connectable to thepiping prior to reuse; and (e) transporting the reclaimed antimicrobialsolution to a reuse location; wherein the rebound antimicrobial solutioncomprises spent antimicrobial solution at the disinfecting stage; andwherein the reclaimed antimicrobial solution has a level of organiccontaminants and particulates that is lower than a level of organiccontaminants and particulates that would be present if the reclaimedantimicrobial solution contained all of the spent antimicrobial solutionfrom the disinfecting stage.
 7. The method of claim 6, wherein the stepof spraying the antimicrobial solution occurs continuously.
 8. Themethod of claim 6, wherein the spraying the antimicrobial solutioncomprises spraying acidified sodium chlorite.
 9. The method of claim 6,wherein the spraying the antimicrobial solution comprises sprayingperoxyacetic acid or peroxyoctanoic acid.
 10. The method of claim 6,wherein the spraying the antimicrobial solution comprises sprayingacetic acid, octanoic acid, citric acid, lactic acid, phosphoric acid,or proprionic acid.
 11. The method of claim 6, wherein the spraying theantimicrobial solution comprises spraying hydrogen peroxide.
 12. Themethod of claim 6, further comprising reconditioning the reclaimedantimicrobial solution before transporting the reclaimed antimicrobialsolution to the reuse location.
 13. The method of claim 6, wherein thereclaimed antimicrobial solution is reused without reconditioning. 14.The method of claim 6, wherein the raw food product is selected from thegroup consisting of poultry, beef, fruits, vegetables, or combinationsthereof.